Automated system for producing and managing rolls of web material

ABSTRACT

A system to produce rolls of web material includes: a production machine ( 1 ) to produce the web material; a winder ( 3 ) to form reels (B) of web material coming from the production machine; an unwinder ( 20 ) to unwind single reels of web material produced by the winder; a group of tools for longitudinal cutting of the web material to divide the web material into strips, including members to position the tools in a transverse direction with respect to the direction of feed of the web material; a rewinder ( 22 ) to rewind the single strips into rolls; a line for packaging ( 9 ) the rolls (R); at least one shuttle ( 11 ) to transfer groups of rolls formed by the rewinder towards the packaging line; and an information system for integrated management of the system.

TECHNICAL FIELD

The present invention relates to systems for the production of rolls ofweb material, in particular although not exclusively rolls or reels ofnonwoven.

PRIOR ART

Nonwoven is a material with many uses in various industrial fields. Itis used, for example, as a component in the production of sanitarynapkins, babies diapers and similar articles of manufacture. Nonwoven isalso utilized to produce filters, garments particularly of thedisposable type, sheets, sanitary articles of various types and otherarticles.

Nonwoven is usually produced continuously by a system or machine with awinder provided at the outlet thereof; the winder is a machine thatcontinuously receives the strip of web material and winds it into reelswith a large diameter, also called parent or master reels. These largereels must subsequently be unwound and rewound cutting the web materialinto strips of a smaller width to produce, in parallel, rolls ofdifferent diametrical and axial dimensions. The dimension of the rollsdepends on the final destination of the semi-finished product. Theserolls are then usually sent to other systems or plants to form thestarting material for production of the finished article.

Machines to produce nonwoven can be carding machines and mechanicalentangling or hydro entangling systems, spun lace systems or othersknown systems.

An example of a winder utilizable downstream of a machine for continuousproduction of a nonwoven is described in EP-A-1245515. In thisparticular type of winder the web material is wound around a windingaxle or mandrel supported between two side panels. The reel being formedis held pressed against a winding roller around which the web materialdelivered from the production machine is fed.

Rewinders, which can have different conformations, are utilized tounwind the reel and rewind it into single rolls after having firstdivided it via longitudinal cutting into single strips. Purely by way ofexample, some rewinders utilizable in the production of nonwoven aredescribed in EP-A-0747308, EP-A-1070675, EP-A-1375400.

The rewinder is equipped with a system of blades and counter-blades orother longitudinal cutting tools. These are positioned transversely withrespect to the direction of feed of the web material, on the basis ofthe dimensions of the strips to be obtained by cutting the web materialfrom the reel. Various systems have been studied for automaticpositioning the blades as a function of the material to be produced. Anexample of device to perform said positioning is described inEP-A-1245354.

Winding mandrels, on which tubular winding cores, corresponding innumber, position and dimension to the number, position and dimension ofthe strips into which the cutting tools divide the web material comingfrom the master reel being unwound, have been fitted, are inserted timeby time in the rewinder. Machines and devices that prepare the mandrelwith the tubular winding cores fitted thereon currently exist. Anexample of a device of this type is described in WO-A-0061480 and in thecorresponding European patent EP-B-1169250.

Downstream of the rewinders the winding mandrels are removed from theformed rolls, which are then sent to packaging.

Currently, integrated systems for management of the various productionsteps from the winder to packaging are not provided. In general, incurrently utilized systems there are three separate primary processes.These are:

-   -   winding of the nonwoven produced by the continuous machine,    -   unwinding, cutting and rewinding,    -   labeling, packaging and palletizing process.

These three processes are separate from one another, and consequentlyfor total production different production data must be entered for thewinding step, for the subsequent cutting and rewinding step and for thefinal packaging step.

The operator in charge of the line must consequently manage the threeproduction processes separately, must enter the production parameters onthe different control panels several times, must control the singleproduction processes on the single control stations and, at each changein production, must repeat all the programming of the three separateprocesses.

This requires considerable management and programming times and the needfor several persons to control and manage the entire process, especiallyin the initial set-up and production change steps. Moreover, the need toenter data several times increases the risk of error during entering ofthe production parameters on the three different management systems.

The presence of three separate production processes makes it impossibleto optimize the processes as a function of the desired parameters(minimization of times as a function of the type of product and otherparameters), and makes it impossible to constantly verify production onall the machinery, manage the traceability of products and the like.These operations are currently performed directly by the operator, andconsequently the production quality and quantity is dependent on thespecific skills of each operator.

OBJECTS AND SUMMARY OF THE INVENTION

According to a first aspect, the invention relates to a system and amethod which overcome, entirely or in part, at least some of thedrawbacks mentioned above.

In substance, according to a first aspect, the invention provides for asystem to produce rolls of web material, comprising in combination atleast the following components: a machine to produce the web material; awinder, which forms reels of web material coming from said productionmachine; an unwinder to unwind single reels of web material produced bysaid winder; a group of tools for longitudinal cutting of the webmaterial, to divide said web material into strips, with members toposition said tools in a transverse direction with respect to thedirection of feed of the web material; a rewinder, to rewind the singlestrips into rolls; a line for packaging the rolls; at least one shuttleto transfer the groups of rolls formed by said rewinder-cutter towardssaid packaging line; an information system for integrated management ofsaid components of the system.

The system can be managed in an integrated way by means of theinformation system, avoiding the need to individually manage separateprocesses such as winding, cutting and rewinding, and packaging.

According to an advantageous embodiment, the information systemcomprises a network server, a database containing information concerningprocess and/or control data; a plurality of computers associated withthe components of the system; a local network connecting said server andsaid computers.

According to an advantageous embodiment, associated with the rewinder isa device to prepare the winding mandrels of the rolls, fitted on whichare winding cores with dimensions and positions corresponding to thepositions and dimensions of the single rolls to be produced, said devicebeing connected to said local network.

In an advantageous embodiment, the line for packaging the rollscomprises a robot for handling the rolls. Said robot can be controlledto pick up single rolls from said at least one shuttle and distributethem on single pallets. Alternatively, means to convey and separate thesingle rolls can be provided. The rolls are unloaded from the shuttleonto a system which allows individual feed, having first performedupending if required, to facilitate gripping of the rolls by the robot.

In an alternative embodiment, the system comprises a handling robotproduced and positioned to pick up (i.e. directly from the shuttle)single rolls positioned with the axis thereof approximately horizontaland rotate them to take them to a position with the axis thereofapproximately vertical.

Further advantageous embodiments and possible additional characteristicsof the system according to the invention are indicated hereunder withreference to some non-limiting embodiments and in the appended claims.

According to a specific aspect, the invention also relates to a robotfor handling rolls of web material, particularly although notexclusively for use in a system of the above type, comprising anarticulated arm, movable according to a plurality of numericallycontrolled axes and supporting a suction head. According to a possibleembodiment, the suction head has a surface for gripping the rollssubstantially flat in shape and approximately semi-circular.Advantageously, the suction head can have suction areas that can beactivated selectively as a function of the diameter of the roll to behandled.

According to a preferred embodiment of the invention, the suction areasare formed of substantially semi-annular portions, in fluid connectionwith a suction duct. Also provided are selection members to selectivelyconnect said substantially semi-annular portions to the suction duct.The selection members can comprise a valve.

In a further embodiment, the head of the robot can have a plurality ofself-closing valves, connected to a suction duct and positioned with thesuction side towards the gripping surface of the suction head of therobot. The self-closing valves can be equipped with respective shut-offmembers which close the valve when there is no surface of a roll to beengaged via said head in front of it.

In a particularly preferred embodiment of the invention, a sensor toactivate suction when the head is in proximity to a roll is associatedwith said head.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood by following the description andaccompanying drawings, which show non-limiting practical embodiments ofthe invention.

More specifically, in the drawing:

FIG. 1 shows a plan diagram of a layout of the system according to oneembodiment;

FIG. 2 shows an enlargement, again in a plan view, of the rewindingarea;

FIG. 3 shows a side view of the labeling machine to close the outsidefree ends of a reel or of a series of rolls delivered from the rewinder;

FIG. 4 shows an axonometric view of the labeling machine in FIG. 3,separate from the remaining part of the structure;

FIG. 5 shows a plan view of the packaging area of a system according toFIG. 1;

FIGS. 6A-6E show enlargements of portions of FIG. 5;

FIG. 7 shows a plan view of a layout of the system in a differentembodiment, limited to the packaging area;

FIGS. 8A, 8B and 8C show a side view of the shuttle and details ofoperation of the robot in the embodiment in FIG. 7;

FIGS. 9 to 16 show illustrative diagrams of the handling system of thesystem according to the invention;

FIGS. 17A and 17B show the head of the robot in a side view and in twodifferent angular positions in a first embodiment;

FIG. 18 shows a view according to XVIII-XVIII in FIG. 17A;

FIGS. 19 and 20 show axonometric views of the head in FIGS. 17A, 17B, 18in two angular positions;

FIG. 21 shows a front view according to XXI-XXI in FIG. 17A;

FIG. 22 shows an axonometric view of the head of the robot in adifferent embodiment; and

FIG. 23 shows an exploded view of the head in FIG. 22.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

FIG. 1 schematically indicates a possible layout of a system accordingto the invention. Reference number 1 generically indicates a machine forcontinuously producing a web material, typically a nonwoven ply or web.The machine 1 can be any machine suitable to form a consolidated ply offibers.

Downstream of the machine 1 is a winder, indicated as a whole with 3 andproduced, for example, as described in EP-A-1245515 or having any othersuitable configuration. The letter B indicates a reel being wound on thewinder 3. Positioned downstream of the winder 3 is a group of devicesindicated as a whole with 5 and comprising, as described hereunder ingreater detail, a rewinder with an unwinder, a group of blades or othertools for longitudinally cutting the web material unwound from a reel Bwith transverse positioning members, a device to prepare winding coreson winding mandrels, a device to extract the mandrels from the assemblyof rolls formed by the rewinder, and a labeling machine to label eachroll coming from the rewinder.

Positioned between the winder 3 and the unit 5 is a storage area 7,which can hold one or more reels coming from the winder 3 and which areto be inserted in the unwinder associated with the rewinder of the unit5. The configuration shown in FIG. 1 also comprises a symmetricalarrangement, indicated with 5′, of the same machines forming the unit 5,to illustrate the possibility of feeding two rewinder units with asingle winder 3.

A packaging or wrapping line, indicated as a whole with 9, and whichwill be described in greater detail hereunder, is associated with thepart of system comprising the units 1, 3, 5 and optionally 5′. In thisline the single rolls produced in parallel by the rewinder of the unit 5are separated and distributed into stacks divided according to product,i.e. placing in each stack rolls with the same dimensions. In this line9 the stack of rolls are also packaged and then wrapped on pallets forsubsequent transport.

A plurality of shuttles 11 transfer the rolls from the rewinder of theunit 5 or 5′ to the packaging line 9. Several shuttles 11 can beprovided, and as well as transferring the rolls to the packaging line 9,they can convey the rolls to an area 11 for quality control andoptionally to an area 13 for manual packaging, thus by-passing packagingline 9. The numeral 15 schematically indicates a station to recharge thebatteries of the shuttles 11.

FIG. 2 schematically represents a plan view of the group of devicesindicated as a whole with 5 in FIG. 1. Numeral 20 indicates the unwindercombined with the rewinder 22, with numeral 23 indicating the tools forlongitudinally cutting the web material delivered from the reel B andnumeral 25 indicating the winding rollers. Positioned downstream of thewinding rollers is an unloading chute 27, which has a cradle of rollerspositioned under a labeling machine 31, which labels the rolls unloadedfrom the winding cradle formed by the rollers 25 and which will bedescribed in greater detail hereunder.

Positioned at the side of the rewinder 21 is the device 33 to preparethe mandrels with the respective tubular cores inserted and lockedthereon. The numeral 35 indicates the system to insert the mandrel andrespective winding cores in the winding area of the rewinder 21. Thedevice 33, 35 can be designed as described in greater detail, forexample, in WO-A-0061480 or in another suitable way.

Reference number 36 indicates an extractor device to extract the mandrelfrom the groups of rolls formed by the rewinder 21. The extractor canalso be designed as disclosed in WO-A-0061480.

FIGS. 3 and 4 respectively show a schematic side view of the rewinderlimited to the winding rollers and to the unloading surface and to thelabeling device 31 associated with said surface.

The unloading surface or chute 27 is equipped with a pair of rollers 37defining a cradle into which the rolls R produced by the rewinder can beunloaded. As these rolls, as is known per se, are wound about a commonmandrel, a series of coaxial rolls having the same diameter, from whichthe winding mandrel is extracted, will be placed on the unloading chute27 at each cycle. The rolls R rest on the rollers 37, which are rotatedto make the rolls R rotate about the axis thereof until the final freeend is facing upward, i.e. towards the head 41 of the labeling machine31, so that the latter can apply self-adhesive labels (for exampleprinted by said head 41) to the tail of each roll. The labels have thedual purpose of preventing the web material from unwinding from the rollin the subsequent handling operations and of marking each roll with acode or other information useful for subsequent operations.

The head 41 is mounted on a carriage 43 which moves on guides forvertical sliding according to the double arrow f45 of a slide 45. Themovement according to f45 allows the head 41 to be moved towards andaway from the unloading surface or chute 27, to allow labeling of rollsR of different diameter. The carriage 43 can translate according to thedouble arrow f43 on a cross-member 47 equipped with sliding guides 49 tolabel in sequence all the rolls placed time by time on the unloadingchute or surface 27. It is understood that, should this be necessary,for example, due to the axial length of the rolls, each roll can beprovided with more than one label.

FIG. 5 schematically shows a possible configuration of the packagingline 9, while FIGS. 6A-6E show an enlargement of subsequent portions ofsaid line.

Reference number 51 indicates a first conveyor onto which the rolls Rfrom the shuttle 11 coming from the rewinder are unloaded. The conveyor51 feeds the single rolls according to the arrow f51 towards an areaprovided with equipment 53 for optional further labeling, e.g. on theperiphery of each roll. According to an advantageous embodiment,illustrated herein, labeling takes place with the roll R lying on avertical plane, i.e. with the axis thereof horizontal, before subsequentupending.

According to a possible embodiment, downstream of the equipment 53 is anupender 55, which upends each roll of the group of rolls unloaded fromthe shuttle onto the conveyor 51 to position it with the axis thereofvertical, i.e. orthogonal, to the plane of the figure. In practice,rolls with small axial dimensions can be upended spontaneously, whilethose with larger axial dimensions can be upended by the upender 55.

The upended rolls R are fed via a conveyor system 57 towards a rollerconveyor 59 from which they can be singly picked up by a robot indicatedas a whole with 61. The robot 61 can place the single rolls on one orother of two conveyors 63A, 63B. For this purpose, the robot 61 has anarm 65 provided with a movement around a plurality of numericallycontrolled axes. As well as picking up the individual rolls R from theroller conveyor 59, the robot 61 can also pick up separator discs DSmade of cardboard or another suitable sheet material, positioned on aspecific support 67 placed within the range of action of the arm 65 ofthe robot 61. In this way, the robot 61 picks up single rolls and placesthem on one or other of the conveyors 63A, 63B, and can place aseparator disc DS on each roll. The conveyors 63A, 63B are associatedwith an assembly of roller conveyors 69 which can feed stacks of rollsformed on the conveyors 63A, 63B towards the subsequent equipmentpositioned along the packaging line to perform outer wrapping andlabeling of the packages of rolls, as well as optional weighing andother operations concerning packaging.

According to an advantageous embodiment of the invention, a machine 71is provided along the roller conveyor 69 to wrap, with a film F, thestack of rolls R positioned time by time in the machine 71.

According to a possible embodiment of the invention, downstream of thewrapping machine 71 a palletization station 73 is positioned, in whichsingle pallets P are inserted under the stack of rolls R, between saidstack and the roller conveyor 69. For this purpose, according to anembodiment of the invention, a lifting member 75 with jaws or grippers76, which grip the stack of rolls R laterally to lift it from the rollerconveyor, is positioned in the station 73.

According to an advantageous embodiment, a further wrapping machine 77is positioned downstream of the palletization station 73, where theassembly formed by the pallet and by the stacks of rolls R is wrappedwith a plastic film.

According to the preferred embodiment illustrated in FIG. 6E, a furtherroller conveyor 79 is positioned downstream of the wrapping machine 77,with which the palletized packages are fed to an external labelingstation 81 and from here to an unloading roller conveyor 83, at theoutlet of which the single pallets are picked up with a fork lift truckor the like (not shown).

The control system of the system described above will be illustrated ingreater detail hereunder on the basis of a series of diagrams. Beforegoing on to describe these aspects, however, it must be observed thatthe system layout, and in particular the packaging line described withreference to FIGS. 5 and 6, is provided purely as an indication and asan example of many possible layouts of the members and means to performpackaging of the stacks of rolls. A different possible configuration andarrangement of the packaging line is illustrated in FIG. 7. FIGS. 8A, 8Band 8C show details of operation of the system in this example ofembodiment.

According to this embodiment, the robot, again indicated with 61, picksup the single rolls R when they are still positioned with their axes A-Ahorizontal on the shuttle 11. Reference number 101 indicates slidingtracks to allow the robot 61 to slide in the direction of the doublearrow f61, to be positioned with the head 61A thereof each time at thelevel of the first roll of each group of rolls R positioned on theshuttle 11 placed in the packaging area. The example illustrated in FIG.7 shows, by way of example, two robots 61 moving on a common guide 101to operate simultaneously on two groups of rolls R conveyed by twoshuttles 11. The shuttle is represented schematically in a side view inFIG. 8A.

FIGS. 8B and 8C schematically illustrate the movement with which therobot 61, by means of the head 61A, positions itself to pick up the rollR from the row of rolls placed on the shuttle 11 (FIG. 8B) and, with arotation of the head (FIG. 8C), it is placed on top of the stack ofrolls R being formed at a station or position Pp for forming stacks ofrolls. The stations Pp for forming the stacks of rolls are alignedparallel to the tracks or rails 101 on the opposite side with respect tothe side from which the rolls are picked up. Said stations Pp can beoccupied by a pallet or by a simple surface shaped to allow the reels tobe picked up by a fork lift truck. A fork lift truck 105, advantageouslydriven automatically, is provided to pick up the single pallets Pp withthe rolls placed thereon or to lift a single stack of rolls, andtransfer them to the second part of the packaging line, where wrappingtakes place. At several stations Pp for forming stacks, several stacksof rolls R with variable dimensions, typically of different height, areformed. The head and tail trimmings indicated with RF are unloaded bythe robot into stacks which are formed in lateral areas 107. The numeral109 indicates areas for storing separator discs DS made of cardboard,plastic or another material, which each robot 61 picks up to place ontop of each roll positioned at the station Pp for forming stacks.

In the second part of the packaging line, the single stack of rolls R isreleased by the fork lift truck 105 onto a conveyor 111 which feeds itaccording to the arrow f111. In an advantageous embodiment a firstwrapping machine 113, substantially equivalent to the wrapping machine71 illustrated in FIG. 6C, is positioned along the conveyor 111. Thewrapping machine 113 wraps the package of rolls before it is transferredto a palletization station 115, substantially equivalent to thepalletization station 73. Here, with members analogous to thoseillustrated in the example of embodiment in FIGS. 6A-6E, the stack ofrolls R is lifted to place a pallet P thereunder. Again advancing alongthe packaging line, the assembly formed of the pallet P with the stackof rolls R on top, is inserted into a further wrapping station 117,substantially equivalent to the final wrapping station illustrated inthe previous embodiment.

FIGS. 9 to 16 schematically show the managing part of the system, theprinciple mechanical components of which have been describedhereinbefore.

In FIG. 9 reference number 150 schematically represents and indicates anEthernet network to which a plurality of computers are connected. Morespecifically, in the diagram in FIG. 9, reference number 151 indicates afirst computer to manage the winder 3, reference number 152 indicates acomputer combined with the rewinder 21, inclusive of unwinder of thereels B, reference number 153 indicates a computer to controlpositioning of the longitudinal cutting tools and of the device 33, 35,37 to prepare the winding mandrels, insert them in the machine andextract them from the completed reels, reference number 154 indicatesthe network server and reference numbers 155 and 156 indicate twocomputers for managing the packaging line. More specifically, thecomputer 155 controls the robot 61, while the computer 156 controls theremaining equipment of the packaging line.

Each of the computers 151-156 is associated with a relative databaseindicated with 151A for the computer 151 and, coherently with 152A,153A, 154A, 155A and 156A for the remaining computers 152-156. These canreside in the single computers, or can be part of a database residing inthe network server. Each database 151A-156A will have architecturesuitable for its specific purpose.

FIG. 10 illustrates again schematically how Ethernet network 150reciprocally connects a plurality of PLCs (Programmable LogicControllers) associated with the various devices of the system. Morespecifically, a PLC 157 to control the winder, a PLC 158 to control therewinder, a PLC 159 to control positioning of the blades or other toolsfor longitudinal cutting of the web material, a PLC 161 to control thedevice to prepare the mandrels with the respective winding cores, PLCs162, 163, 164 to control the packaging line and a PLC 165 to control themandrel extractor are connected to the network 150. The numeral 166schematically indicates a PLC associated with one of the transfershuttles 11 and 167 indicates a transmission board from the server tothe PLC 166 on board the shuttle 11.

FIG. 11 schematically represents the flow of data inside the systemdescribed hereinbefore. The entire process can be divided into varioussteps, and more precisely:

-   -   a production process of the web material in the continuous        machine,    -   a winding process in the winder, with forming of master reels B,    -   an unwinding and cutting process, and a rewinding process in the        rewinder,    -   a handling or logistics process, concerning moving the rolls        produced by the rewinder towards storage areas and/or towards        the packaging line, and    -   an actual packaging process.

The data concerning the production order and more specificallyparameters concerning the actual production of the web material, i.e.the production recipe of the nonwoven, the winding parameters,represented for example by the pressure and torque applied to the reelduring formation, the cutting parameters sent to the rewinder, to thedevice to prepare the winding mandrels and to the device to position thelongitudinal cutting blades, parameters which prevalently concern theposition of the cutting blades, and then the axial dimension of therolls to be formed, the quantity of web material to wind on each rolland the diameter of each roll, the winding tension, the winding pressureand any other data utilized in the rewinding section, are sent to thevarious processes.

The data coming from the packaging line are then conveyed to the serverto be analyzed and compared with the production order data.

FIG. 12 shows a block diagram representing the functional process tasks,carried out by each piece of equipment described above. FIG. 13schematically shows the exchange of information between the various PLCsconnected to the network.

FIG. 14 shows a diagram of transmission of information between thevarious databases in relation to processing of master reels indicated as“master i”, where “i” indicates the sequential number of the reel. Ascan be observed in the diagram in FIG. 14, the data of the master reelsare progressively entered in the main database during their production.These reels are then unwound on the unwinder and rewound in the rewinderforming series of rolls on winding mandrels sequentially inserted intothe rewinder. Each series is composed of a plurality of rolls ofdifferent formats. In the diagram, “finished roll i” i=1, 2 . . . nindicate the single winds obtained on mandrels sequentially inserted inthe rewinder starting from a single master reel (indicated with master 1in the diagram). As each winding on a mandrel (“finished roll i”) isdivided into a plurality of rolls of different heights (i.e. differentaxial lengths), these are then sent to packaging to be distributed intovarious packages, where each package contains rolls of the samedimension. This is represented in the diagram in FIG. 14, indicatingwith “slit 1”, “slit 2”, . . . “slit n” the single rolls obtained oneach winding mandrel. The data concerning this division of the rollsinto packages in the packaging line are also loaded in the maindatabase.

FIG. 15 shows an example of division of a single winding on a singlemandrel “finished roll i”, divided into three distinct formats and, morespecifically, into the format with a height of 300 mm (four rolls), aheight of 400 mm (two rolls) and a height of 500 mm (three rolls). Twoside trimmings of 50 mm each are also indicated (the drawing is not toscale). FIG. 5 also schematically represents cutting tools (blade andcounter-blade) positioned at the level of the longitudinal cuts to bemade on the web material coming from the main reel B to allow winding ofthe single rolls.

FIG. 16 schematically shows how the data concerning the packages C to beobtained starting from a single master reel B can be set. In the exampleshown, three types of rolls with formats of 300, 400 and 500 mm aretheoretically produced (see FIG. 15). For each type of roll the numberof rolls for each pack (i.e. for each package on a single pallet P) andthe total number of packs to be produced is indicated. The diameter thateach roll must have is also indicated. Assuming that the types 1, 2 and3 of product must be wound simultaneously, the three diameters of thethree types of product will be equal.

In the figures described above the robot 61 is represented without meansto grip the rolls, in order to simplify the drawing. However, accordingto a particularly advantageous embodiment of the invention, the head ofthe robot has a particular configuration, illustrated hereunder in twodifferent embodiments with reference to FIGS. 17 to 23.

The first embodiment of the gripping member mounted on the head of therobot 61 is illustrated in FIGS. 17A to 21, where FIGS. 17A and 17B showside views of the head with the gripping members represented in twodifferent positions, more specifically a position to grip a roll withthe axis in a horizontal position (FIG. 17B) and a position to releasethe roll in the position with vertical axis (FIG. 17A). FIG. 18 is aplan view according to line XVIII-XVIII in FIG. 17A and FIG. 21 is afront view according to line XXI-XXI in FIG. 17A, while FIGS. 19 and 20are axonometric views of the gripping members in the two positionsindicated schematically in FIGS. 17A and 17B.

In an advantageous embodiment of the invention, the suction head has aroll gripping surface, indicated with 501 and having an approximatelyflat semi-circular shape. More specifically, the surface 501 has acircular central area 501A and a semicircular extension 501B. Accordingto a possible embodiment of the invention, the gripping surface 501 isdivided (FIG. 19) into five suction areas 503A, 503B, 503C, while thecircular central area has no suction, as it coincides with the axialhole of the rolls.

The suction area 503A has a substantially annular shape and is delimitedby two concentric annular projections, defined inside which is acompartment which, by means of suction holes 505A, is placed in fluidconnection with a flexible suction duct 507, in turn connected to asuction line. The numeral 505B indicates suction apertures associatedwith the two areas 503B developing in a portion of annular surfaceconcentric to the central portion 501A. The numeral 505C indicatessuction holes that connect the areas 503C to the suction line 507.

A slide valve operated by an actuator 507 (FIG. 20), for example of theelectromagnetic type, is associated with the suction holes 505A, 505Band 505C. Operation is such to selectively open or close the suctionholes 500A, 500B, 500C. In this way, it is possible to alternativelyplace only the holes 505A in fluid connection with the suction duct 507,keeping the holes 505B and 505C closed, or to also place the holes 505Band optionally also the holes 505C in connection with the duct 507.Opening or closing of the suction holes 505A, 505B, 505C takes place asa function of the diameter of the roll to be engaged. The larger thediameter of the roll is, the greater the number of annular orsemi-annular areas 503A, 503B, 503C to be placed in connection with thesuction line 507 will be. This guarantees maximum grip as a function ofthe diameter of the roll and minimum air consumption.

According to an advantageous embodiment a proximity sensor 511 and astrip 513 cooperating with an inductive sensor are associated with thesurface to grip the rolls indicated with 501. The strip 513 is bent whenthe suction head and more precisely the gripping surface 501 comes intocontact with the front surface of the roll to be engaged with thesuction head. Deflection of the strip energizes the inductive sensorwhich enables suction. The proximity sensor 511 can be composed of asonar to determine the distance from the roll.

The gripping surface 501 is mounted oscillating on an axle 521 supportedby a frame 523. The numeral 525 indicates a piston-cylinder actuator,the rod 527 of which is hinged by means of an axle 529 to tabs 531connected rigidly to the gripping surface 501. The piston-cylinderactuator 525 is supported on the frame 523 analogously to theoscillating axle 521 of the gripping surface 501. Constraint between thepiston-cylinder actuator 525 and the frame 523 allows oscillation of thepiston-cylinder actuator so that this takes the correct position (seeFIGS. 17A, 17B) in each angular position of the gripping surface 501with respect to the axle 521. The numeral 533 indicates a plate withwhich the frame 523 is fastened to the head end of the arm of the robot61. Finally, the numeral 535 indicates a flexible channel for thewiring.

FIGS. 22 and 23 show a modified embodiment of the members to grip therolls. The same numbers indicate the same or equivalent parts to thoseof the embodiment in FIGS. 17 to 21.

In this embodiment rather than the gripping surface 501 beingcharacterized by annular or circular areas that can be selectivelyplaced in communication with the suction line via a slide valve, adifferent configuration of the suction members is provided to allowautomatic activation or deactivation of a smaller or larger suctionsurface. According to this embodiment, the suction gripping surface 601has a central portion 501A with a substantially circular shape having acentral area without suction, surrounded by suction areas 502 and 504arranged concentrically about a central axle. Positioned about thiscentral axle are two portions with annular sector 501D equipped withholes 506. As can be seen in the exploded view in FIG. 23, the holes 506are produced in a plate 508, which defines the outer surface of thesectors 501D and behind which a filter 510 is placed. Placed behind thefilter 501 is a frame 512, on which self-closing valves 514 are mounted,with number and position corresponding to the number and layout of theholes 506. These are valves which place the holes in connection with thesuction area behind them, in fluid connection with the duct 507.

The self-closing valves 514 are configured so that they remain openwhile a limited flow rate of air passes therethrough. When the flow rateincreases beyond a certain limit, the valve automatically closes. Inthis way, when the robot is operating and the front suction grippingsurface 501 is brought into contact with the flat surface of a roll,this flat surface intercepts a certain number of holes 506 as well asthe areas 502 and 504. These are always in fluid connection with thesuction duct 507, once opening of a shut off valve has been enabled bythe sensor 513, while the holes 506 will be in fluid connection with thesuction duct 507 only where the front surface of the roll to be engagedvia the surface 501 is in front of the holes 506. The self-closingvalves 514 which are at the level of holes 506 not closed by the frontsurface of the roll to be picked up close automatically due to the freeflow of air through the holes 506. This solution allows the area throughwhich suction is to be produced to be regulated automatically, withoutthe use of valves with relative controlled actuators. It is alsopossible to produce a system in which the entire suction surface isproduced with holes 506 and self-closing valves behind them.

Self-closing valves are known per se and do not therefore require to bedescribed herein. For example, model ISV ⅛″ valves produced by FESTO AG& Co KG. (Germany) can be utilized for this purpose.

It is understood that the drawing only shows an example provided by wayof a practical illustration of the invention, which can vary in formsand arrangements without however departing from the scope of the conceptunderlying the invention. Any reference numerals in the appended claimsare provided to facilitate reading of said claims with reference to thedescription and to the drawing, and do not limit the scope of protectionrepresented by the claims.

The invention claimed is:
 1. A system to produce rolls of web material,comprising: a production machine to produce the web material; a winder,which forms reels of web material coming from said production machine;an unwinder to unwind single reels of web material produced by saidwinder; a group of tools for longitudinal cutting of the web material,to divide said web material into strips, with members to position saidtools in a transverse direction with respect to a direction of feed ofthe web material; a rewinder, to rewind the single strips into rolls; aline for packaging the rolls; at least one shuttle to transfer groups ofrolls formed by said rewinder towards said packaging line; aninformation system for integrated management of the system.
 2. A systemas claimed in claim 1, wherein said information system comprises anetwork server, a database containing information concerning processdata and/or control data, a plurality of computers associated with thesystem and a local network connecting said server and said computers. 3.A system as claimed in claim 2, wherein said packaging line of the rollscomprises a robot for handling the rolls.
 4. A system as claimed inclaim 3, wherein said packaging line comprises a conveyor to conveyrolls from said shuttle to a position to be picked up by said handlingrobot.
 5. A system as claimed in claim 3, wherein said robot iscontrolled to pick up single rolls from said at least one shuttle anddistribute them on single pallets.
 6. A system as claimed in claim 1,wherein associated with said rewinder is a device to prepare windingmandrels of the rolls, wherein winding cores are fitted on said windingmandrels, said winding cores having dimensions and positionscorresponding to the dimensions and positions of single rolls to beproduced, said device being connected to a local network.
 7. A system asclaimed in claim 6, wherein said packaging line of the rolls comprises arobot for handling the rolls.
 8. A system as claimed in claim 1, whereinsaid packaging line of the rolls comprises a robot for handling therolls.
 9. A system as claimed in claim 8, wherein said robot iscontrolled to pick up single rolls from said at least one shuttle anddistribute them on single pallets.
 10. A system as claimed in claim 8,wherein said packaging line comprises a conveyor to convey rolls fromsaid shuttle to a position to be picked up by said handling robot.
 11. Asystem as claimed in claim 10, wherein an upender is associated withsaid conveyor, to upend said rolls from a position in which an axisthereof is approximately horizontal to a position in which the axisthereof is approximately vertical.
 12. A system as claimed in claim 11,wherein said upender upends single rolls individually.
 13. A system asclaimed in claim 8, wherein said handling robot is designed and arrangedto pick up single rolls positioned with an axis thereof approximatelyhorizontal and rotate them to take them to a position with an axisthereof approximately vertical.
 14. A system as claimed in claim 8,wherein said handling robot is controlled to pick up separator elementsto place between superimposed rolls on a same stack.
 15. A system asclaimed in claim 1, wherein said packaging line comprises a first deviceto wrap, with a plastic film, single packs, each of said single packscomprising a stack of said rolls.
 16. A system as claimed in claim 1,wherein said packaging line comprises a second device to wrap, with aplastic film, single packs, each of said single packs comprising a stackof said rolls and a pallet.
 17. A system as claimed in claim 1, furthercomprising a labeling machine positioned between a winding cradle ofsaid rewinder and said packaging line, to apply adhesive labels to atail end of the rolls formed by said rewinder before packaging.
 18. Asystem as claimed in claim 17, wherein said labeling machine comprises aprinting member to print information on said label.
 19. A system asclaimed in claim 17, wherein said labeling machine is movable along ahorizontal axis and a vertical axis, to label rolls with diameters ofdifferent dimensions.
 20. A system as claimed in claim 17, wherein saidlabeling machine cooperates with a device for angular orientation of therolls before labeling.
 21. A system as claimed in claim 20, wherein saiddevice for angular orientation of the rolls is positioned on said atleast one shuttle.
 22. A system as claimed in claim 20, wherein saiddevice for angular orientation of the rolls is associated with anunloading surface of the rewinder.
 23. A system as claimed in claim 20,wherein said device for angular orientation of the rolls comprises apair of rollers defining a cradle to support and rotate the rolls.
 24. Asystem as claimed in claim 1, further comprising an auxiliary packagingstation, to package rolls or reels of considerable axial length.
 25. Asystem as claimed in claim 1, said information system furthercomprising, in addition to a server and interfaced with a network: afirst computer associated with said winder and functionally connected toa database containing data concerning the reels formed by said winder; asecond computer associated with said rewinder and functionally connectedto a database containing data concerning the unwinding process of thereels and forming of said rolls; a third computer, associated with saidgroup of longitudinal cutting tools and functionally connected to adatabase containing data concerning said rolls; at least a fourthcomputer associated with said packaging line and functionally connectedto a database containing data concerning packaging of said rolls.
 26. Asystem as claimed in claim 25, wherein said third computer is alsoassociated with said device for preparing winding mandrels of the rolls.27. A system as claimed in claim 25, further comprising a fifth computerassociated with said packaging line and functionally associated with adatabase containing data concerning packaging of said rolls.
 28. Asystem as claimed in claim 27, wherein said fourth computer is in chargeof controlling and managing a robot for handling the rolls.
 29. A systemas claimed in claim 1, further comprising: a first PLC for managing saidwinder; a second PLC for managing said rewinder; a third PLC formanaging positioning of said tools for longitudinal cutting of the webmaterial; a fourth PLC for managing a device for preparing windingmandrels of the rolls; a fifth PLC for managing said at least onetransfer shuttle; a plurality of PLCs for managing the packaging line.30. A system as claimed in claim 29, further comprising a PLC formanaging a member for extracting the winding mandrels from the rollsformed by said rewinder.
 31. A system as claimed in claim 1, whereinassociated with said rewinder is a device to prepare winding mandrels ofthe rolls, fitted on which are winding cores with dimensions andpositions corresponding to the dimensions and positions of single rollsto be produced, said device being connected to a local network.
 32. Asystem as claimed in claim 31, wherein said packaging line of the rollscomprises a robot for handling the rolls.